Cable assemblies and optical connector assemblies employing a unitary alignment pin and translating element

ABSTRACT

Cable assemblies, optical connector assemblies, and optical connector subassemblies employing a translating element and a unitary alignment pin are disclosed. In one embodiment, an optical connector assembly includes a connector housing defining a connector enclosure and a connector housing opening, a unitary alignment pin including a first pin portion and a second pin portion, and a translating element including a first bore, a second bore, and an optical interface. The unitary alignment pin is secured within the connector enclosure. The first pin portion is disposed within the first bore and the second pin portion is disposed within the second bore such that the translating element translates along the first pin portion and the second pin portion within the connector enclosure.

BACKGROUND

1. Field of the Disclosure

The technology of the disclosure relates to optical connectors having atranslating element, wherein the translating element may be utilized forfacilitating optical connections.

2. Technical Background

Benefits of optical fiber include extremely wide bandwidth and low noiseoperation. Because of these advantages, optical fiber is increasinglybeing used for a variety of applications, including, but not limited to,broadband voice, video, and data transmission. Fiber optic networksemploying optical fiber are being developed and used to deliver voice,video, and data transmissions to subscribers over both private andpublic networks. These fiber optic networks often include separatedconnection points linking optical fibers to provide “live fiber” fromone connection point to another connection point. In this regard, fiberoptic equipment is located in data distribution centers or centraloffices to support optical fiber interconnections. Additionally, opticalcable assemblies may be utilized in consumer applications to communicatebetween personal computing devices and auxiliary electronic device, suchas smart phones, media players, external storage components, and thelike.

SUMMARY OF THE DETAILED DESCRIPTION

Fiber optic connectors are provided to facilitate optical connectionswith optical fibers for the transfer of light. For example, opticalfibers can be optically connected to another optical device, such as alight-emitting diode (LED), laser diode, or opto-electronic device, forlight transfer. As another example, optical fibers can be opticallyconnected to other optical fibers through mated fiber optic connectors.In any of these cases, it is important that the end face of an opticallyconnected optical fiber be precisely aligned with the optical device orother optical fiber to avoid or reduce coupling loss. For example, theoptical fiber is disposed through a ferrule that precisely locates theoptical fiber with relation to the fiber optic connector housing.

Flat end-faced multi-fiber ferrules may be provided to more easilyfacilitate multiple optical fiber connections between the fiber opticconnector supporting the ferrule and other fiber optic connectors orother optical devices. In this regard, it may be important that fiberoptic connectors be designed to allow the end faces of the opticalfibers disposed in the ferrule to be placed into contact or closelyspaced with an optical device or other optical fiber for light transfer.In conventional multi-fiber, fiber optic connectors, the excess fiber isremoved by laser cleaving and the remaining protruding fiber precisionpolished to form a highly planar fiber array. When these connectors aremated, the end faces touch providing for low loss. This high precisionpolishing is costly and difficult.

Gradient index (GRIN) lenses offer an alternative to high precisionpolishing. GRIN lenses focus light through a precisely controlled radialvariation of the lens material's index of refraction from the opticalaxis to the edge of the lens. The internal structure of this indexgradient can dramatically reduce the need for high precision polishingand results in a simple, compact lens. This allows a GRIN lens with flatsurfaces to collimate light emitted from an optical fiber or to focus anincident beam into an optical fiber. The GRIN lens can be provided inthe form of a glass rod that is disposed in a lens holder as part of afiber optic connector. The flat surfaces of a GRIN lens allow easybonding or fusing of one end to an optical fiber disposed inside thefiber optic connector with the other end of the GRIN lens disposed onthe ferrule end face. The flat surface on the end face of a GRIN lenscan reduce aberrations, because the end faces can be polished to beplanar to slightly inset with respect to the end face of the ferrule.The flat surface of the GRIN lens allows for easy cleaning of end facesof the GRIN lens. It is important that the lens holder assembly bedesigned with internal holders that place and secure the GRIN lenses inalignment with the desired angular accuracy to avoid or reduce couplingloss. Optical connectors having the unitary alignment pins andtranslating elements disclosed herein may be optically connected to oneor more optical fibers in another fiber optic connector or to an opticaldevice, such as a laser-emitting diode (LED), laser diode,vertical-cavity surface-emitting laser (VCSEL), or opto-electronicdevice for light transfer.

Embodiments disclosed herein are directed to optical cable assemblies,optical connector assemblies, and optical connector subassemblies havinga unitary alignment pin on which a translating element maintaining anoptical interface may translate within a housing. Non-limiting examplesof such optical connectors include plugs and receptacles. In oneembodiment, the translating element maintains one or more GRIN lenses.The unitary alignment pin has a first pin portion and a second pinportion, and is fabricated from a single component rather than two ormore components. Use of a single component may reduce complexity andcost. The translating element may include first and second bores thataccept first and second pin portions, respectively. The translatingelement, which may be biased toward an opening of the connector housingby one or more bias members, may translate on the first and second pinportions within the connector housing. When the translating element isin an unconnected state and positioned toward the connector housingopening, the optical interface is easily accessible to a user forcleaning purposes. Upon connection to a mated optical connector, such asa receptacle, the translating element translates back within theconnector housing by contact with a face of the mated optical connector.

In this regard, in one embodiment, an optical connector assemblyincludes a connector housing defining a connector enclosure and aconnector housing opening, a unitary alignment pin including a first pinportion and a second pin portion, and a translating element including afirst bore, a second bore, and an optical interface. The unitaryalignment pin is secured within the connector enclosure. The first pinportion is disposed within the first bore and the second pin portion isdisposed within the second bore such that the translating elementtranslates along the first pin portion and the second pin portion withinthe connector enclosure.

In another embodiment, an optical connector subassembly includes a guideframe, a unitary alignment pin coupled to the guide frame, a translatingelement, and first and second bias members. The guide frame includes abase portion, a first arm portion, and a second arm portion. The firstarm portion and the second arm portion extend from the base portion suchthat there is a gap between the first arm portion and the second armportion. The guide frame is configured to be disposed in a connectorhousing. The unitary alignment pin includes a first pin portion and asecond pin portion and is secured to the guide frame at the baseportion. The first pin portion and the second pin portion are positionedwithin the gap between the first arm portion and the second arm portion.The translating element includes a first bore, a second bore, and anoptical interface. The first pin portion is disposed within the firstbore and the second pin portion is disposed within the second bore. Thefirst bias member is disposed about the first pin portion between thetranslating element and the base portion of the guide frame, and thesecond bias member is disposed about the second pin portion between thetranslating element and the base portion of the guide frame such thatthe translating element translates along the first pin portion and thesecond pin portion.

In yet another embodiment, a cable assembly includes an opticalconnector body, an optical cable extending from a rear portion of theoptical connector body, a plug housing extending from a front surface ofthe optical connector body, a unitary alignment pin having a first pinportion and a second pin portion, and translating element. The opticalcable has at least one optical fiber. The plug housing defines anoptical connector opening. The unitary alignment pin is disposed withinthe optical connector body and the plug housing. The translating elementincludes a first bore, a second bore, and at least one GRIN lens. Thefirst pin portion is disposed within the first bore and the second pinportion is disposed within the second bore such that the translatingelement translates along the first pin portion and the second pinportion. The at least one optical fiber is optically coupled to the atleast one GRIN lens.

Additional features and advantages will be set forth in the detaileddescription which follows, and in part will be readily apparent to thoseskilled in the art from that description or recognized by practicing theembodiments as described herein, including the detailed description thatfollows, the claims, as well as the appended drawings.

It is to be understood that both the foregoing general description andthe following detailed description present embodiments, and are intendedto provide an overview or framework for understanding the nature andcharacter of the disclosure. The accompanying drawings are included toprovide a further understanding, and are incorporated into andconstitute a part of this specification. The drawings illustrate variousembodiments, and together with the description serve to explain theprinciples and operation of the concepts disclosed.

BRIEF DESCRIPTION OF THE FIGURES

FIG. 1 is a front perspective view of an exemplary optical connectorassembly of an exemplary cable assembly;

FIG. 2 is a front perspective view of an exemplary receptacle configuredto mate with the exemplary optical connector depicted in FIG. 1;

FIG. 3A is a top perspective view of an exemplary optical connectorsubassembly wherein the translating element is biased in a forwardposition;

FIG. 3B is a bottom perspective view of the exemplary optical connectorsubassembly depicted in FIG. 3A;

FIG. 3C is a top perspective view of the exemplary optical connectorsubassembly depicted in FIG. 3A wherein the translating element is in aretracted position;

FIG. 4A is a top perspective view of an exemplary unitary alignment pinof the exemplary optical connector subassembly depicted in FIGS. 3A-3C;

FIG. 4B is a bottom perspective view of the exemplary unitary alignmentpin depicted in FIG. 4A;

FIG. 5 is a top perspective view of an exemplary unitary alignment pinwherein the rear portion is in the same plane as first and second pinportions;

FIG. 6 is a top perspective view of an exemplary unitary alignment pinhaving a single bent portion;

FIG. 7 is a top perspective view of an exemplary unitary alignment pinhaving an off centerline rear portion;

FIG. 8 is a front, top perspective view of an exemplary single-piecetranslating element;

FIG. 9A is a front, top exploded view of an exemplary two-piecetranslating element;

FIG. 9B is a front, bottom exploded view of the exemplary two-piecetranslating element depicted in FIG. 9A;

FIG. 9C is a front, top perspective view of an assembled exemplarytwo-piece translating element depicted in FIG. 9A; and

FIG. 10 is a front, top perspective view of an exemplary single-piecetranslating element having a wide bore and a circular bore.

DETAILED DESCRIPTION

Reference will now be made in detail to the embodiments, examples ofwhich are illustrated in the accompanying drawings, in which some, butnot all embodiments are shown. Indeed, the concepts may be embodied inmany different forms and should not be construed as limiting herein;rather, these embodiments are provided so that this disclosure willsatisfy applicable legal requirements. Whenever possible, like referencenumbers will be used to refer to like components or parts.

Embodiments disclosed herein include optical cable assemblies, opticalconnector assemblies, and optical connector subassemblies employing atranslating element having an optical interface for passing opticalsignals, and a unitary alignment pin on which the translating element isfree to translate. Non-limiting examples of connectors include plugs andreceptacles. The translating elements described herein are configured totranslate within a connector housing on a unitary alignment pin. Theunitary alignment pin is a single, unitary component having a first pinportion and a second pin portion that are disposed within first andsecond bores through the translating element. The unitary alignment pinmay reduce complexity and cost over the use of multiple alignment pincomponents. The translating element is biased toward an opening of theconnector housing such that when the optical connector is in adisengaged state, a coupling surface and optical interface of thetranslating element is accessible to a user for the wiping away ofdebris and liquid. When the optical connector is coupled to a matedoptical connector, such as a receptacle of an electronic device, forexample, the translating element is translated back into the connectorhousing along the first and second pin portions of the unitary alignmentpin.

The unitary alignment pin may be configured as a precision wire that isbent into the desired form having a first and second pin portions onwhich the translating element slides. In some embodiments, the unitaryalignment pin comprises bent portion that act as engagement andalignment features for precise placement within the optical connectorassembly. As described in detail below, the configuration of the unitaryalignment pin may take on a variety of forms.

In one embodiment, the translating element comprises one or moreinternal groove alignment features configured to secure one or moregradient index (GRIN) lenses in the translating element. The groovealignment features are also configured to accurately align the end facesof the GRIN lenses. In another embodiment, the translating elementcomprises one or more refractive lens at the optical interface foroptically coupling the translating element to a mated connector.

A fiber optic connector assembly containing the unitary alignment pinsdisclosed herein may be optically connected to one or more opticalfibers in another fiber optic connector or to an optical device, such asa laser-emitting diode (LED), laser diode, vertical-cavitysurface-emitting laser (VCSEL), or opto-electronic device for lighttransfer. As a non-limiting example, the optical connectors disclosedherein can be provided as part of a plug or receptacle containing one ormore optical fibers for establishing optical connections.

In this regard, FIG. 1 is a perspective view of an assembled exemplarycable assembly 100 comprising an optical connector assembly 101employing a translating element 110 configured to support and alignoptical components 122 of an optical interface 120 to pass opticalsignals through the lens holder assembly. The optical connector assembly101 in the illustrated embodiment is configured as a male plugconnector. For example, the optical connector assembly 101 may be afiber optic connection plug that supports optical components forestablishing optical connections and communication over the cableassembly 100.

More specifically, the optical connector assembly 101 generallycomprises a connector housing 105 having a plug housing 111 extendingfrom a front surface 106. The plug housing 111 defines a plug portionthat may be inserted into a receptacle 270 (FIG. 3). In otherembodiments, the optical connector assembly 101 may not include a plughousing 111. In such embodiments, the optical connector assembly 101 maybe configured as a female optical connector, wherein the connectorhousing 105 defines an opening to expose a coupling surface 126 of thetranslating element 110.

The optical connector assembly 101 further comprises optical fibers 104disposed in a cable 102 extending from a rear surface 107 of theconnector housing 105. The plug housing 111 comprises engagement tabs113 a, 113 b that are configured to engage mated engagement tabs 275 a,275 b of a receptacle housing 272, as described below with reference toFIG. 3.

In the illustrated embodiment, the plug housing 111 defines an opticalconnector opening 123 that exposes the translating element 110 that ismaintained in a connector enclosure defined in part by the plug housing111. As depicted in FIGS. 1, 3A-3C, the translating element 110 of theparticular embodiment is configured to translate along an x-axis (i.e.,an optical axis of the optical connector assembly 101) within theconnector housing 105. Still referring to FIG. 1, the illustratedtranslating element 110 comprises a coupling surface 126. Opticalcomponents, such as GRIN lenses 122, refractive lenses, and the like,are exposed at the coupling surface 126 to align the optical components,such as the optical fibers 104, within the translating element to amated optical connector. Although embodiments described herein reciteGRIN lenses, other optical components may be disposed within thetranslating element 110, such as optical fiber stubs and waveguides, forexample.

The GRIN lenses 122 focus light through a precisely controlled radialvariation of the lens material's index of refraction from the opticalaxis to the edge of the lens. The internal structure of this indexgradient can dramatically reduce the need for tightly controlled surfacecurvatures and results in a simple, compact lens. This allows the GRINlenses 122 with flat surfaces to collimate light emitted from theoptical fibers 104 or to focus an incident beam into the optical fibers104. In this embodiment, the GRIN lenses 122 are provided in the form ofglass rods that are disposed in the translating element 110. The flatend face surfaces of the GRIN lenses 122 allow simple optical couplingof ends of the GRIN lenses 122 to end portions of the optical fibers 104inside the optical connector assembly 101, with the other end of theGRIN lenses 122 disposed on the coupling surface 126 of the translatingelement 110. The flat end face surfaces of the GRIN lenses 122 can alsoreduce aberrations.

Further, with continuing reference to FIG. 1, the end faces of the GRINlenses 122 can be planar to slightly inset to the coupling surface 126(e.g., within 0-25 μm). In some embodiments, the end faces of the GRINlenses 122 may be slightly recessed with respect to the coupling surface126 to avoid physical contact with the GRIN lenses of a mated opticalconnector to prevent damage to the GRIN lenses 122. If the offsetdistance between the end faces of the GRIN lenses 122 is too large, itmay create a dirt collection recess. In alternative embodiments the endfaces of the GRIN lenses 122 may be flush with the coupling surface 126.The flat surface of the GRIN lenses 122 allows for easy cleaning of endfaces of the GRIN lenses 122. As will be discussed in more detail below,the translating element 110 may be designed with internal alignmentfeatures that support and align the GRIN lenses 122 in alignment withtranslating element 110 and the optical connector assembly 101 to avoidor reduce coupling loss between the GRIN lenses 122 and opticalcomponents optically connected to the GRIN lens 122 through a mating tothe optical connector assembly 101.

The exemplary translating element 110 of the optical connector assembly101 depicted in FIG. 1 comprises a first bore 121 a and a second bore121 b. The first and second bores 121 a, 121 b fully extend through thebody of the translating element 110. As described in detail below, theoptical connector assembly 101 comprises a unitary alignment pin 132having a first pin portion 135 a and a second pin portion 135 b. Thefirst pin portion 135 a is disposed within the first bore 121 a of thetranslating element and the second pin portion 135 b is disposed withinthe second bore 121 b of the translating element. The translatingelement 110 may translate back and forth along the x-axis (i.e., theoptical axis of the optical connector assembly) on the first and secondpin portions 135 a, 135 b within the connector enclosure defined by theplug housing 111 and the connector housing 105.

The illustrated optical connector assembly 101 further comprises a guideframe 130 comprising a first arm portion 131 a and a second arm portion131 b that is disposed within a connector enclosure defined by the plughousing 111. The guide frame 130 is described in detail below withreference to FIGS. 3A-3C. Generally, the first and second arm portion131 a, 131 b act as a guide for the translation of the translatingelement 110 within the plug housing 111 and the connector housing 105.The first arm portion 131 a and the second arm portion 131 b of theguide frame 130 of the illustrated embodiment are configured to define afirst opening 140 a and a second opening 140 b within the plug housing111 that are adjacent to the translating element 110. A first electricalcontact 141 a may be positioned on the first arm portion 131 a andexposed within the first opening 140 a and a second electrical contact141 b may be positioned on the second arm portion 131 b and exposedwithin the second opening 140 b. The first and second openings may beconfigured to accept engagement prongs 282 a, 282 b (see FIG. 3) of amated optical connector assembly to robustly couple the opticalconnector assembly 101 to the mated optical connector assembly byresisting external angular forces upon the optical connector assembly101 that may disturb the optical connection between the coupledcomponents. The first and second electrical contacts 141 a, 141 b may beconfigured to pass electrical power and/or data across the cableassembly 100. In such an embodiment, electrical conductors may span thelength of the cable 102.

In other embodiments, the first and second arm portions 131 a, 131 b maynot define opening within the plug housing 111 for receipt of engagementprongs. In this embodiment, the first and second arm portions 131 a, 131b have a face that is approximately flush with respect to the plughousing 111 at the opening 123. In still further embodiments, the firstand second arm portions 131 a, 131 b may define first and secondopenings 140 a, 140 b wherein the first and second electrical contactsare not provided.

FIG. 2 depicts a mated optical connector assembly configured as areceptacle 270 configured to be mated to the optical connector assembly101 depicted in FIG. 1. It should be understood that receptacle 270 isprovided as an example, and other configurations are also possible. Thereceptacle 270 may provide a communications port for an electronicdevice, such as, but not limited to, a personal computer, an electronicdata storage device, a tablet computer, a mobile communications device,and an application specific computing device. The receptacle 270illustrated in FIG. 2 generally comprises a receptacle housing 272 thatis coupled to a printed circuit board (PCB) 271, which may be a PCBmaintained within a housing of an electronic device. The exemplaryreceptacle housing 272 comprises mounting tabs 275M which may be used tocouple the receptacle housing 272 to the PCB 271, such as by the use ofsolder or an adhesive. The receptacle housing 272 further comprisesengagement tabs 275 a, 275 b that are configured to be removably engagedwith the engagement tabs 113 a, 113 b of the plug housing 111 when thetwo components are coupled together.

The receptacle 270 further comprises a lens holder assembly 280 disposedwithin an enclosure defined by the receptacle housing 272 such that agap 281 exists between an outer surface of the lens holder assembly 280and an inner surface of the receptacle housing 272. The gap 281 isconfigured to receive the plug housing 111 when the optical connectorassembly 101 is inserted into the receptacle 270. The illustrated lensholder assembly 280 comprises a seamless, planar mating face 276 that isconfigured to couple with the coupling surface 126 of the translatingelement 110 of the optical connector assembly 101. Although theillustrated lens holder assembly 280 is depicted as a single-piececomponent in FIG. 3, embodiments are not limited thereto. As an exampleand not a limitation, the lens holder assembly 280 may comprise amulti-component assembly comprising a lens holder body and a recessedcover. Further, a multi-component receptacle lens holder assembly mayalso have groove alignment features as described above.

GRIN lenses 278 may be disposed within the lens holder assembly 280 suchthat end faces of the GRIN lenses 278 are planar to slightly inset withrespect to the mating face 276 (e.g., within 0-50 μm). Other opticalcomponents may be utilized for the optical interface, such as refractivelenses, fiber stubs, fiber ends, waveguides, and the like. The GRINlenses 278 (or other optical components) should be arranged within thelens holder assembly 280 for alignment with the GRIN lenses 122 (orother optical components) of the optical connector assembly 101 when theoptical connector assembly 101 is mated with the receptacle 270.

The lens holder assembly 280 additionally comprises a first bore 279 aand a second bore 279 b adjacent to the GRIN lenses 278 and configuredto receive the first and second pin portions 135 a, 135 b of the opticalconnector assembly 101, respectively, when the optical connectorassembly 101 is inserted into the receptacle 270. The first and secondpin portions 135 a, 135 b of the optical connector assembly 101 and thefirst and second bores 279 a, 279 b of the receptacle 270 provide anoptical alignment of the mated GRIN lenses 122, 278. The first andsecond bores 279 a, 279 b may also comprise a sleeve 277 a, 277 b as abushing element to reduce friction between the first and second pinsportions 135 a, 135 b and the inner surface of the first and secondbores 279 a, 279 b. The sleeve may be made out of a lubricious material,such as, but not limited to, sintered bronze. Sleeves may also beprovided in the first and second bores 121 a, 121 b of the translatingelement 110.

First and second engagement prongs 282 a, 282 b may be provided adjacentto the lens holder assembly 280 in embodiments where the guide frame 130of the optical connector assembly 101 defines first and second openings140 a, 140 b. The first and second engagement prongs 282 a, 282 b areconfigured to be slideably disposed within the first and second openings140 a, 140 b of the optical connector assembly 101. The illustratedreceptacle 270 includes a first receptacle electrical contact 283 alocated on an underside surface of the first engagement prong 282 a, anda second receptacle electrical contact 283 b located on an undersidesurface of the second engagement prong 282 b. The first and secondreceptacle electrical contacts 283 a, 283 b are configured to beslideably and electrically coupled to the first and second electricalcontacts 141 a, 141 b of the optical connector assembly 101 when thefirst and second engagement prongs 282 a, 282 b are positioned withinthe first and second openings 140 a, 140 b of the optical connectorassembly 101 to provide electrical connectivity between the opticalconnector assembly 101 and the receptacle 270. It should be understoodthat, in other embodiments, the receptacle 270 may not include the firstand second engagement prongs or the first and second receptacleelectrical contacts.

As described in more detail below, when the optical connector assembly101 is pushes into the receptacle 270 by the user, the coupling surface126 of the translating element 110 contacts the mating face 276 of thelens holder assembly 280 such that the mating face 276 pushes thetranslating element 110 back into the connector housing 105.

Referring now to FIGS. 3A-3C, an exemplary optical connector subassembly150 configured to be disposed within a connector enclosure defined bythe connector housing 105 and the plug housing 111 is illustrated. FIG.3A is a top perspective view of the exemplary optical connectorsubassembly 150, while FIG. 3B is a bottom perspective view of theexemplary optical connector subassembly 150 depicted in FIG. 3A. FIG. 3Cis a top perspective view of the exemplary optical connector subassembly150 depicted in FIG. 3A wherein the translating element 110 istranslated back along the x-axis in a negative direction.

The optical connector subassembly 150 generally comprises the guideframe 130, the translating element 110, the unitary alignment pin 132,and first and second bias members 136 a, 136 b. The first and second armportions 131 a, 131 b define an open region 151 in which the translatingelement 110 is positioned and may translate along the x-axis. The firstand second arm portions 131 a, 131 b act as a guide for the translationof the translating element 110 such that it is prevented fromsubstantial movement along the y-axis. Movement along the z-axis may beprevented by the interior surface of the plug housing 111. The first andsecond arm portions 131 a, 131 b may include grooves or other features(not shown) to ensure slideable engagement with the translating element110.

The unitary alignment pin 132 is configured to be secured to the guideframe 130. The unitary alignment pin 132 may mechanically be engagedwith the guide frame 130 and/or be secured using a suitable adhesive.FIGS. 4A and 4B depict the exemplary unitary alignment pin 132 depictedin FIGS. 3A-3C in greater detail. The unitary alignment pin 132 may beconfigured as a precision wire that is bent, molded or otherwise workedinto the desired configuration that provides the first pin portion 135 aand the second pin portion 135 b, wherein the first and second pinportions 135 a, 135 b are substantially parallel with respect to oneanother, and separated by a distance d that corresponds to a distancebetween the first and second bores 121 a, 121 b of the translatingelement 110.

The unitary alignment pin 132 illustrated in FIGS. 4A and 4B have afirst bent portion 139 a and a second bent portion 139 b that transitiona rear portion 134 of the unitary alignment pin 132 into first andsecond pin portions 135 a, 135 b, respectively. The first and secondbent portions 139 a, 139 b define two protruding portions that protrudeaway from the first and second pin portions 135 a, 135 b along they-axis. These protruding portions (i.e., first and second bent portions139 a, 139 b) are used as engagement mechanisms to couple the unitaryalignment pin 132 to the guide frame 130 in the embodiment depicted inFIGS. 3A-3C. Referring now to FIGS. 3A-3C, the first and second arms 131a, 131 b each comprise an engagement feature 137 a, 137 b proximate abase portion 143 of the guide frame 130. The engagement features 137 a,137 b protrude inwardly from the first and second arms 131 a, 131 balong the y-axis. The first and second bent portions 139 a, 139 b may bepositioned between the engagement features 137 a, 137 b and the baseportion 143 of the guide frame 130 (e.g., by an interference fit). Inthis manner, the unitary alignment pin 132 may be secured to the guideframe 130, which is then disposed within the connector housing 105 andthe plug housing 111. The first and second bent portions 139 a, 139 bmay also be secured to the engagement features 137 a, 137 b by asuitable adhesive, for example.

The rear portion 134 of the unitary alignment pin 132 of the illustratedembodiment is off centerline with respect to the z-axis. In other words,the rear portion 134 is in a plane that is different from the plane inwhich the first and second pin portions 135 a, 135 b are positioned. Asshown in FIGS. 3A-3C, the base portion 143 of the guide frame 130 mayinclude a tab feature 133 that extends from the base portion 143 alongthe positive x-axis and is configured to support the rear portion 134 ofthe unitary alignment pin 132 as well as provide a stopping surface forthe translating element 110 when it is retracted within the connectorenclosure. Referring specifically to FIG. 3A, the base portion 143 ofthe guide frame 130 further comprises a fiber groove 137 through whichthe optical fibers 104 may pass between the translating element 110 andthe cable 102. Because the rear portion 134 of the unitary alignment pin132 is off centerline, the optical fibers 104 may pass under the rearportion 134 and through the fiber groove 137.

The optical connector subassembly may further comprise first and secondbias members 136 a, 136 b. In the illustrated embodiment, the first andsecond bias members 136 a, 136 b are configured as compression springs,wherein the first bias member 136 a is positioned about the first pinportion 135 a and the second bias member 136 b is positioned about thesecond pin portion 135 b. In alternative embodiments, the bias membersmay not be positioned about the first and second pin portions 135 a, 135b, a single bias member may be used, or more than two bias members maybe used. The first and second bias members 136 a, 136 b bias thetranslating element 110 toward the opening 123 of the plug housing 111such that the coupling surface 126 is accessible to a user for cleaningwhen the optical connector assembly 101 is in a disengaged state.

The exemplary translating element 110 includes first and second notchportions 128 a, 128 b that are adjacent to the first and second bores121 a, 121 b, respectively. The ends first and second arm portions 131a, 131 b comprise a first stop feature 142 a and a second stop feature142 b, respectively. The first and second stop features 142 a, 142 bextend from the first and second arm portions 131 a, 131 b inwardlyalong the y-axis. The first and second notch portions 128 a, 128 bengage the first and second stop features 142 a, 142 b when thetranslating element 110 is biased forward along the x-axis, therebymaintaining the translating element 110 within the guide frame 130.Other configurations to maintain the translating element 110 within theguide frame 130 may also be provided.

Referring now to FIG. 3C, the optical connector subassembly 150 isdepicted in an engaged state wherein the translating element 110 hasmoved back into the guide frame 130 negatively along the x-axis due toinsertion of the optical connector assembly 101 (not shown in FIG. 3C)into a mated receptacle (not shown in FIG. 3C). Translation of thetranslating element 110 as shown in FIG. 3C exposes the first and secondpin portions 135 a, 135 b for insertion into corresponding bores of themated receptacle to optically align the optical components (e.g., GRINlenses 122) with optical components of the receptacle to pass opticalsignals therebetween. Upon disconnection of the optical connectorassembly 101 from the receptacle, the first and second bias members 136a, 136 b may push the translating element back toward the front of theoptical connector assembly 101, as shown in FIG. 1. It is noted that insome embodiments, the unitary alignment pin may be utilized in opticalconnectors wherein the coupling surface (e.g., on the translatingelement) does not translate on the first and second pin portions.Rather, in such embodiments, the both translating element 110 and theunitary alignment pin 132 are free to move within the connectorenclosure. For example, the unitary alignment pin 132 may be fixedwithin the translating element 110, wherein the first and second pinportions 135 a, 135 b extend from the coupling surface 126 of thetranslating element 110. As an example and not a limitation, the unitaryalignment pins described herein may be utilized in Multiple-FiberPush-On (MPO) connectors.

Unitary alignment pin configurations other than the configurationdepicted in FIGS. 2A-4B are contemplated. FIGS. 5-7 depict alternativeunitary alignment pin configurations. It should be understood thatembodiments are not limited to the unitary alignment pins depicted inthe figures, as many other alternative configurations are possible. FIG.5 depicts a unitary alignment pin 232 having a first and second pinportion 235 a, 235 b that extend from a rear portion 234. Unlike theunitary alignment pin 132 depicted in FIGS. 4A and 4B, the unitaryalignment pin 232 depicted in FIG. 5 does not include the first andsecond bent portions 139 a, 139 b. Rather, the unitary alignment pin 232of FIG. 5 comprises a “U” shaped precision wire. The unitary alignmentpin 232 may be secured a guide frame in a variety of ways, such asplacement in groove features and application of adhesive, for example.

FIG. 6 depicts an embodiment of a unitary alignment pin 332 having asingle bent portion 339 that is proximate a center point of the rearportion 334. The single bent portion 339 defines a protrusion that maymechanically mate with a corresponding engagement feature of the guideframe (e.g., by insertion of the single bent portion 339 into a hole orgroove within the base of the guide frame). First and second pinportions 335 a, 335 b extend from the rear portion 334.

FIG. 7 depicts an embodiment of a unitary alignment pin 432 having anoff centerline rear portion 434. Similar to the rear portion 134 of theembodiment depicted in FIGS. 4A and 4B, the off centerline rear portion134 is offset along the z-axis with respect to the first and second pinportions 435 a, 435 b. The unitary alignment pin 432 depicted in FIG. 7does not include a bent portion as the embodiments depicted in FIGS. 4A,4B and 6. The guide frame may be designed to accept and secure theunitary alignment pin 432, such as inclusion of a groove to position theoff centerline rear portion 434 as well as pass the optical fibers 104.

Referring now to FIG. 8, the illustrated translating element 110 is asingle-piece component that generally comprises a coupling surface 126,a rear surface 124, and one or more optical components 122 (e.g., GRINlenses) maintained within bores 127 that extend from the couplingsurface 126 to the rear surface 124. Ends of the optical components 122are exposed at least at the coupling surface 126. The translatingelement 110 may be shaped such that it may translate within the plughousing 111. As described above, the translating element 110 may includea first notch portion 128 a and a second notch portion 128 b forengaging the first and second arm portions 131 a, 131 b.

In alternative embodiments, the translating element is a two-piececomponent employing a cover and alignment grooves to maintain opticalcomponents, such as GRIN lenses. FIGS. 9A-9C depict a two-piecetranslating element 210 in partially exploded and assembled views. Thetwo-piece translating element 210 comprises an upper component 225 and alower component 290 configured as a cover that fits within an opening235 defined by the upper component 225. The assembled two-piecetranslating element 210 has a similar shape and configuration as thesingle-piece translating element 110 depicted in FIGS. 2A-3C. Similar tothe single piece translating element 110, the two-piece translatingelement 210 has a coupling surface 226 that interfaces with a matedoptical connector and a rear surface 229 that receives the opticalfibers 104.

The upper component 225 comprises the first and second through-holes 221a, 221 b through which the first pin and second pin may be positioned,as described above. The upper component 225 further comprises inwardlyangled walls 260 and 261 that slope from a bottom surface of the uppercomponent to an inner surface 223. The inwardly angled walls 260, 261define an opening 235 configured to receive the lower component 290. Theupper component 225 may further include the first and second notchportions 228 a, 228 b for engaging the first and second arm portions 131a, 131 b.

The inner surface 223 of the upper component 225 comprises one or moregrooves 227 that extend from the coupling surface 226 to the rearsurface 229. An optical component 222, such as a GRIN lens, ispositioned within each groove 227. The two-piece translating element 210may enable easier placement of the optical components 222 because of theaccess to the grooves 227 provided by the opening 235. The grooves 227may be of any appropriate geometry. In the illustrated embodiment, thegrooves 227 have straight walls and a curved floor to accommodate thecylindrical optical components 222, and the inner surface 223 is planerwith respect to a top surface of the optical components 222. However,other configurations are also possible, such as V-shaped grooves orrectangular grooves. The optical components 222 may be secured withinthe grooves 227 by a suitable adhesive, for example.

The lower component 290, which acts as a cover for the opticalcomponents 222, has an upper, optical component contacting surface 292,a bottom surface 293, and two angled walls 294, 295 that are configuredto interface with inwardly angled walls 260, 261 of the upper component225, respectively. The lower component also has a coupling surface 226′and a rear surface 229′. The lower component 290 may be positionedwithin the opening 235 of the upper component 225 after positioning theoptical components 222 within the grooves 227 such that the opticalcomponent contacting surface 292 contacts the bottom surface 293 of theupper component 225 and the optical components 222, and angled walls294, 295 of the lower component 290 contact inwardly angled walls 260,261 of the upper component 225, respectively (FIG. 9C). The lowercomponent 290 may be secured to the upper component 225 by a suitableadhesive.

The coupling surface 226′ of the lower component 290 should besubstantially planar with respect to the coupling surface 226 of theupper component 225 and the end faces 428 of the optical components whenthe lower component 290 is mated to the upper component 225. In oneembodiment, the coupling surface 226′ of the lower component 290, thecoupling surface 226 of the of the upper component 225, and the endfaces of the optical components 222 are within 10 μm of each other.

FIG. 10 depicts a translating element 510 as described above, exceptthat one of the bores within the coupling surface 526 is configured as aslot. In the illustrated embodiment, the second bore 521 b is wider thanthe first bore 521 a. A receptacle may also include a lens holderassembly having two bores where one bore is wider than the other.

It should now be understood that embodiments described herein aredirected to cable assemblies, optical connector assemblies, and opticalconnector subassemblies employing a unitary alignment pin on which atranslating element comprising an optical interface is positioned. Theunitary alignment pin may reduce assembly complexity as well as reduceoverall cost of the connector assembly.

As non-limiting examples, the GRIN lenses disclosed herein may comprisea generally cylindrical glass member having a radially varying index ofrefraction, the glass member having a length such that the lens has apitch of less than about 0.23. As used herein, the pitch length of thelens, Lo, is 2π/A; the fractional pitch, or, hereafter, pitch, isL/Lo=LA/2π, where L is the physical length of the lens. In variousembodiments, the pitch is between about 0.08 and 0.23, such as, forexample, lenses having pitches of 0.22, 0.21, 0.20, 0.19, 0.18, 0.17,0.16, 0.15, 0.14, 0.13, 0.12, 0.11, 0.10, 0.09 and 0.08. Someembodiments relate to small diameter lenses, such as lenses having adiameter less than or equal to about one (1) mm, for example, 0.8 mm. Incertain embodiments, lenses having a diameter less than about 1 mm areoperative to produce a beam having a mode field diameter between about350 μm and 450 μm when illuminated with a beam having a mode fielddiameter of about 10.4 μm.

Examples of optical devices that can interface with the GRIN lensesdisclosed in the lens holder assemblies disclosed herein include, butare not limited to, fiber optic collimators, DWDMs, OADMs, isolators,circulators, hybrid optical devices, optical attenuators, MEMs devices,and optical switches.

Further, as used herein, it is intended that terms “fiber optic cables”and/or “optical fibers” include all types of single mode and multi-modelight waveguides, including one or more optical fibers that may beupcoated, colored, buffered, ribbonized and/or have other organizing orprotective structure in a cable such as one or more tubes, strengthmembers, jackets or the like. The optical fibers disclosed herein can besingle mode or multi-mode optical fibers. Likewise, other types ofsuitable optical fibers include bend-insensitive optical fibers, or anyother expedient of a medium for transmitting light signals. An exampleof a bend-insensitive, or bend resistant, optical fiber is ClearCurve®Multimode fiber commercially available from Corning Incorporated.Suitable fibers of this type are disclosed, for example, in U.S. PatentApplication Publication Nos. 2008/0166094 and 2009/0169163, thedisclosures of which are incorporated herein by reference in theirentireties.

Many modifications and other embodiments of the embodiments set forthherein will come to mind to one skilled in the art to which theembodiments pertain having the benefit of the teachings presented in theforegoing descriptions and the associated drawings. Therefore, it is tobe understood that the description and claims are not to be limited tothe specific embodiments disclosed and that modifications and otherembodiments are intended to be included within the scope of the appendedclaims. It is intended that the embodiments cover the modifications andvariations of the embodiments provided they come within the scope of theappended claims and their equivalents. Although specific terms areemployed herein, they are used in a generic and descriptive sense onlyand not for purposes of limitation.

We claim:
 1. An optical connector assembly comprising: a connectorhousing defining a connector enclosure and a connector housing opening;a unitary alignment pin formed of a single, unitary wire and comprisinga first pin portion and a second pin portion, wherein the unitaryalignment pin is secured within the connector enclosure; and atranslating element comprising a first bore, a second bore, and anoptical interface, wherein the first pin portion is disposed within thefirst bore and the second pin portion is disposed within the second boresuch that the translating element translates along the first pin portionand the second pin portion within the connector enclosure and withrespect to the connector housing exposing the first pin portion and thesecond pin portion for mating.
 2. The optical connector assembly ofclaim 1, wherein the unitary alignment pin comprises an engagementfeature configured to maintain the unitary alignment pin within theconnector enclosure.
 3. The optical connector assembly of claim 1,wherein the unitary alignment pin comprises a first bent portion and asecond bent portion that protrude away from the first pin portion andthe second pin portion, respectively, along a y-axis.
 4. The opticalconnector assembly of claim 3, wherein the first bent portion and thesecond bent portion mate with engagement features within the connectorenclosure.
 5. The optical connector assembly of claim 4, wherein theunitary alignment pin further comprises a rear portion located in aplane that is different from a plane defined by the first pin portionand the second pin portion.
 6. The optical connector assembly of claim1, further comprising a first bias member disposed about the first pinportion and a second bias member disposed about the second pin portion.7. The optical connector assembly of claim 1, wherein the opticalinterface comprises at least one GRIN lens.
 8. An optical connectorsubassembly comprising: a guide frame comprising a base portion, a firstarm portion, and a second arm portion, wherein the first arm portion andthe second arm portion extend from the base portion such that there is agap between the first arm portion and the second arm portion, and theguide frame is configured to be disposed in a connector housing; aunitary alignment pin formed of a single, unitary wire and comprising afirst pin portion and a second pin portion, wherein the unitaryalignment pin is secured to the guide frame at the base portion, and thefirst pin portion and the second pin portion are positioned within thegap between the first arm portion and the second arm portion; atranslating element comprising a first bore, a second bore, and anoptical interface, wherein the first pin portion is disposed within thefirst bore and the second pin portion is disposed within the secondbore; and a first bias member and a second bias member, wherein thefirst bias member is disposed about the first pin portion between thetranslating element and the base portion of the guide frame, and thesecond bias member is disposed about the second pin portion between thetranslating element and the base portion of the guide frame such thatthe translating element translates along the first pin portion and thesecond pin portion and with respect to the connector housing exposingthe first pin portion and the second pin portion for mating.
 9. Theoptical connector subassembly of claim 8, wherein the unitary alignmentpin comprises a first bent portion and a second bent portion thatprotrude away from the first pin portion and the second pin portion,respectively, along a y-axis.
 10. The optical connector subassembly ofclaim 8, wherein: the first arm portion comprises a first engagementfeature; the second arm portion comprises a second engagement feature;the unitary alignment pin comprises a first bent portion and a secondbent portion; and the first bent portion is positioned between the firstengagement feature and the base portion of the guide frame, and thesecond bent portion is positioned between the second engagement featureand the base portion of the guide frame.
 11. The optical connectorsubassembly of claim 8, wherein the base portion of the guide framefurther comprises a tab feature that protrudes from a surface of thebase portion, wherein the tab feature is configured to provide astopping surface for the translating element.
 12. The optical connectorsubassembly of claim 11, wherein the unitary alignment pin furthercomprises a rear portion located in a plane that is different from aplane defined by the first pin portion and the second pin portion suchthat the unitary alignment pin is bent around the tab feature.
 13. Theoptical connector subassembly of claim 8, wherein the base portionfurther comprises a fiber groove for maintaining optical fibers.
 14. Theoptical connector subassembly of claim 8, the optical interfacecomprises at least one GRIN lens.
 15. The optical connector subassemblyof claim 8, further comprising a first electrical contact on the firstarm portion of the guide frame and a second electrical contact on thesecond arm portion of the guide frame.
 16. A cable assembly comprising:an optical connector body; an optical cable extending from a rearportion of the optical connector body, the optical cable comprising atleast one optical fiber; a plug housing extending from a front surfaceof the optical connector body, wherein the plug housing defines anoptical connector opening; a unitary alignment pin formed of a single,unitary wire and comprising a first pin portion and a second pinportion, wherein the unitary alignment pin is disposed within theoptical connector body and the plug housing; and a translating elementcomprising a first bore, a second bore, and at least one GRIN lens,wherein: the first pin portion is disposed within the first bore and thesecond pin portion is disposed within the second bore such that thetranslating element translates along the first pin portion and thesecond pin portion for exposing the first pin portion and the second pinportion for mating and with respect to the plug housing; and the atleast one optical fiber is optically coupled to the at least one GRINlens.
 17. The cable assembly of claim 16, wherein the unitary alignmentpin comprises a first bent portion and a second bent portion thatprotrude away from the first pin portion and the second pin portion,respectively, along a y-axis.
 18. The cable assembly of claim 16,further comprising a guide frame comprising a base portion, a first armportion, and a second arm portion, wherein: the guide frame is disposedwithin the optical connector body and the plug housing; the first armportion and the second arm portion extend from the base portion suchthat there is a gap between the first arm portion and the second armportion; and the unitary alignment pin is secured to the guide frame atthe base portion of the guide frame, and the first pin portion and thesecond pin portion are positioned within the gap between the first armportion and the second arm portion.
 19. The cable assembly of claim 18,further comprising a first bias member and a second bias member, whereinthe first bias member is disposed about the first pin portion betweenthe translating element and the base portion of the guide frame, and thesecond bias member is disposed about the second pin portion between thetranslating element and the base portion of the guide frame.
 20. Thecable assembly of claim 18, wherein: the first arm portion comprises afirst engagement feature; the second arm portion comprises a secondengagement feature; the unitary alignment pin comprises a first bentportion and a second bent portion; and the first bent portion ispositioned between the first engagement feature and the base portion ofthe guide frame, and the second bent portion is positioned between thesecond engagement feature and the base portion of the guide frame. 21.The cable assembly of claim 18, wherein the base portion of the guideframe further comprises a tab feature that protrudes from a surface ofthe base portion, wherein the tab feature is configured to provide astopping surface for the translating element.
 22. The cable assembly ofclaim 21, wherein the unitary alignment pin further comprises a rearportion located in a plane that is different from a plane defined by thefirst pin portion and the second pin portion such that the unitaryalignment pin is bent around the tab feature.
 23. The cable assembly ofclaim 18, further comprising a first electrical contact on the first armportion of the guide frame and a second electrical contact on the secondarm portion of the guide frame.
 24. An optical connector assemblycomprising: a connector housing defining a connector enclosure and aconnector housing opening; a unitary alignment pin formed of a single,unitary wire and comprising a first pin portion and a second pinportion, wherein the unitary alignment pin is disposed within theconnector enclosure; and a coupling surface comprising a first bore, asecond bore, and an optical interface, wherein the first pin portion isdisposed within the first bore and the second pin portion is disposedwithin the second bore such that the coupling surface and the unitaryalignment pin translate within the connector enclosure and with respectto the connector housing while exposing the first pin portion and thesecond pin portion for mating.